JP2023531966A - Protective packaging and its manufacturing method - Google Patents

Abstract

Kind Code: A1 The present disclosure is directed to methods of manufacturing protective packaging materials, and protective packaging materials manufactured using the disclosed methods. These packaging materials are biodegradable, compostable and/or recyclable.

Description

The present disclosure is directed to methods of manufacturing protective packaging materials and protective packaging materials manufactured using the disclosed methods.

Padded envelopes made of kraft paper and plastic padding are common in today's market. These products meet packaging requirements at reasonable cost. However, these products are harmful to the environment as they cannot be recycled through conventional paper or plastic recycling processes. As a result, most of these padded envelopes end up in landfills. Padded envelopes containing expandable microspheres provide a recyclable option for paper, but not all of the ingredients are completely biodegradable, compostable, or recyclable.

There is a need for lightweight, biodegradable, compostable, and/or more recyclable padded envelopes that are available at a reasonable cost of sale.

The present disclosure is directed to compositions comprising 1% to 40% wood fiber, 0.5% to 20% binder, 0.2% to 10% surfactant, 10% to 95% water, and 0% to 30% additives by weight. Methods of making these compositions are also described. The present disclosure is also directed to and described in a method of making wood fiber-containing foams, including intermediate foams and hyperexpansion foams, which can be used, for example, in the manufacture of padded packaging materials.

Figures 1A, 1B, and 1C show compositions of the present disclosure before mixing (1A), during mixing (1B), and after mixing and aeration to produce an intermediate foam (1C). FIG. 2 shows a conventional oven dried foam containing regenerated fiber samples. See Example 5. FIG. 3 shows an embodiment of the present disclosure comprising a 2 inch long intermediate foam pattern that was heated using microwaves to produce a hyperexpanded foam (see also Example 7). FIG. 4A shows a "wet" ("medium") foam composition of the present disclosure placed on a paper substrate. FIG. 4B shows a hyperexpansion foam exhibiting expansion in the x, y and z directions produced by microwave heating the intermediate foam composition of FIG. 4A. FIG. 5A shows a "wet" ("intermediate") foam composition of the present disclosure (1 g, 2 inch wet line). FIG. 5B shows a hyperexpansion foam produced by microwave heating the intermediate hyperexpansion foam composition of FIG. 5A. FIG. 6 shows a foam application pattern of the present disclosure on a hyperexpanded web (paper) substrate, long lines (0.56 g of intermediate foam), short lines (0.19 g of intermediate foam), thickness of laminate with paper is about 0.1-0.15 inches. FIG. 7 shows a microwave treated hyperexpanded foam of an embodiment of the present disclosure (see also Example 5). FIG. 8 shows an embodiment of the present disclosure showing a decrease in the overall size of a 0.5 g dot of an intermediate foam of the present disclosure (left, before NaCl addition; right, after NaCl addition) due, at least in part, to increased density and collapse of the intermediate foam (see also Example 6). FIG. 9 shows 0.25 g dots of intermediate foam of the present disclosure after microwave drying of an embodiment of the present disclosure (see also Example 8). FIG. 10A shows a preferred hyperexpanded foam of the present disclosure comprising 5% by weight recycled fibers and 5% by weight softwood fibers after microwave treatment (see also Example 10). FIG. 10B shows an embodiment of the present disclosure comprising 5 wt % regenerated fibers and 5 wt % softwood fibers after treatment with convective heat (conventional oven) (see also Example 10). FIG. 11A shows an intermediate foam (0.25 g wetting element) of the present disclosure (see also Example 11). FIG. 11B shows a hyperexpanded foam of the present disclosure (0.25 g element, left 100% microwave power for 30 seconds; right 30% microwave power for 60 seconds) (see also Example 11).

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure.

When a range of values is provided, unless the context clearly dictates otherwise (e.g., for groups containing a certain number of carbon atoms, where each number of carbon atoms falling within the range is provided), each intervening value is to the tenth of the unit of the lower limit, and it is understood that between the upper and lower limits of the range and any other stated or intervening value within the stated range are encompassed within the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding both of the included limits are also included in the disclosure.

As used in this specification and the appended claims, the articles “a” and “an” are used herein to refer to one or more (e.g., at least one) of the grammatical objects of the article, unless the context clearly indicates otherwise. By way of example, "element" means one element or more than one element.

The present disclosure is directed to compositions comprising wood fibers, binders, surfactants, water, and optional additives suitable for use in, for example, padded packaging materials. These compositions can combine with air to form "wet foams" or "intermediate foams," the terms being used interchangeably herein. The resulting intermediate foam can be applied to one or more web substrates. Application of dielectric heat to the intermediate foam of the present disclosure expands the intermediate foam in each of the x, y and z planes, i.e., in each of the x, y and/or z directions, producing a "super-expanded foam" or "dry foam," which terms may be used interchangeably herein.

While not wishing to be bound by any particular theory, expansion is believed to be caused by the rapid release of water vapor/steam from the intermediate foam. Surprisingly, expansion in the x, y and/or z directions is not achieved using conventional heating methods. While not wishing to be bound by any particular theory, it is believed that conventional heating methods cannot remove water fast enough to produce hyperexpanded foams. The resulting hyperexpansion foam-containing products can be used to produce environmentally friendly packaging materials that provide padding, protection, and/or insulation. Products that can be manufactured according to the disclosed methods include, for example, envelopes, padded envelopes, corrugated packaging, cushioning materials for packaging/protection during shipping, all forms of packaging, biodegradable film packaging, thermal insulation packaging, and the like.

In a preferred embodiment, the composition of the present disclosure comprises from about 1% to about 40% by weight wood fiber, from about 0.5% to about 20% by weight binder, from about 0.2% to about 10% by weight surfactant, from about 10% to about 95% by weight water, and from 0% to about 30% by weight additives.

In some aspects, the compositions of the present disclosure include from about 1% to about 40% by weight wood fiber, such as from 1% to 40% by weight wood fiber. In some aspects, the composition includes 1% to 5% by weight wood fiber. In some aspects, the composition includes 1% to 10% by weight wood fiber. In some aspects, the composition includes 1% to 20% by weight wood fiber. In some aspects, the composition includes 1% to 30% by weight wood fiber. In some aspects, the composition includes 5% to 15% by weight wood fiber. In some aspects, the composition includes 15% to 25% by weight wood fiber. In some aspects, the composition includes 5% to 40% by weight wood fiber. In some aspects, the composition includes 1% to 5% by weight wood fiber. In some aspects, the composition includes 10% to 40% by weight wood fiber. In some aspects, the composition includes 15% to 40% by weight wood fiber. In some aspects, the composition includes 20% to 40% by weight wood fiber. In some aspects, the composition includes 25% to 40% by weight wood fiber. In some aspects, the composition includes 30% to 40% by weight wood fiber. In some aspects, the composition includes 35% to 40% by weight wood fiber. For example, the compositions of the present disclosure contain 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40% by weight. of wood fibers.

Wood fibers used in the compositions of the present disclosure can be virgin or regenerated fibers. Virgin or regenerated fibers can be hardwood fibers, such as fibers made from deciduous trees. The wood fibers used in the compositions of the present disclosure can be softwood fibers, such as fibers made from softwoods. The wood fibers used in the compositions of the present disclosure can be a combination of hardwood and softwood fibers. Preferably, the wood fibers used in the compositions, foams and methods of the present disclosure are softwood virgin wood fibers, particularly softwood virgin kraft pulp. The wood fibers used in the compositions of the present disclosure can be kraft pulp fibers, fluff pulp fibers, northern bleached softwood kraft (NBSK) pulp fibers, southern bleached softwood kraft (SBSK) pulp fibers, virgin pulp fibers, bleached virgin pulp fibers, bleached virgin softwood, newsprint, recycled newsprint, recycled pulp fibers, deinked pulp fibers, bleached pulp fibers, or combinations thereof or combinations thereof. In some aspects, the wood fibers used in the compositions of the present disclosure comprise kraft pulp fibers. In some aspects, the wood fibers used in the compositions of the present disclosure comprise fluff pulp fibers. In some aspects, the wood fibers used in the compositions of the present disclosure comprise NBSK fibers. In some aspects, the wood fibers used in the compositions of the present disclosure comprise SBSK fibers. In some aspects, the wood fibers used in the compositions of the present disclosure comprise regenerated fibers. In some aspects, the wood fibers used in the compositions of the present disclosure comprise deinked fibers. In some aspects, the wood fibers used in the compositions of the present disclosure comprise bleached fibers.

Wood fibers used in the compositions of the present disclosure can include any type of wood fiber typically used in the manufacture of paper products. According to the present disclosure, wood fibers suitable for use in the disclosed compositions and methods include, for example, spruce fibres, pine fibres, fir fibres, western hemlock fibres, balsam fibres, cedar fibres, or combinations thereof. In some aspects, the wood fibers used in the compositions of the present disclosure comprise spruce fibers. In some aspects, the wood fibers used in the methods and compositions of the present disclosure are pine fibers. In some aspects, the wood fibers used in the compositions of the present disclosure comprise fir fibers. In some aspects, the wood fibers used in the methods and compositions of the present disclosure comprise western hemlock fibers. In some aspects, the wood fibers used in the methods and compositions of the present disclosure comprise balsam fibers. In some aspects, the wood fibers used in the methods and compositions of the present disclosure comprise cedar fibers. In some aspects, in addition to wood fibers, synthetic fibers may be added to form the composition. Synthetic fibers can be made from polymeric materials including, but not limited to, polyester fibers and/or acrylonitrile fibers.

According to the present disclosure, wood fibers suitable for use in the disclosed compositions and methods have fiber lengths from about 0.5 mm to about 5 mm, such as from 0.5 mm to 5 mm. The length of the softwood fibers can be about 2-4 mm (0.08-0.16 inches). The length of the hardwood fibers can be about 0.5-1.5 mm (0.02-0.06 inches). Regenerated fibers can have a shortened length of about 0.01 to 5 mm. In some aspects, the wood fibers used in the disclosed methods have fiber lengths between 0.5 mm and 4 mm. In some aspects, the wood fibers used in the disclosed methods have fiber lengths between 0.5 mm and 3 mm. In some aspects, the wood fibers used in the disclosed methods have fiber lengths between 0.5 mm and 2 mm. In some aspects, the wood fibers used in the disclosed methods have fiber lengths between 0.5 mm and 1 mm. In some aspects, the wood fibers used in the disclosed methods have fiber lengths of 1 mm to 4 mm. In some aspects, the wood fibers used in the disclosed methods have fiber lengths between 2 mm and 4 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 3mm to 4mm. For example, the wood fibers used in the disclosed method may be 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3. It can have a fiber length of 3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4 mm.

According to the present disclosure, wood fibers suitable for use in the disclosed compositions and methods have a fiber width of about 20 μm to about 35 μm, such as 20 μm to 25 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 20 μm to 25 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 20 μm to 30 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 25 μm to 30 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 30 μm to 35 μm. For example, wood fibers used in the disclosed methods and compositions can have fiber lengths of 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, or 35 μm.

Wood fibers suitable for use in the disclosed compositions and methods have a weight of from about 5 million fibers per gram to about 30 million fibers per gram, such as from 5 million fibers per gram to 30 million fibers per gram. In some aspects, the wood fibers of the present disclosure have a weight of 5-10 million fibers per gram. In some aspects, the wood fibers of the present disclosure have a weight of 10-15 million fibers per gram. In some aspects, the wood fibers of the present disclosure have a weight of 15-20 million fibers per gram. In some aspects, the wood fibers of the present disclosure have a weight of 20-25 million fibers per gram. In some aspects, the wood fibers of the present disclosure have a weight of 25-30 million fibers per gram. For example, wood fibers suitable for use in the disclosed methods and compositions are 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22 per gram. It can have a weight of 1 million, 23 million, 24 million, 25 million, 26 million, 27 million, 28 million, 29 million or 30 million fibers.

Wood fibers suitable for use in the disclosed compositions and methods can have a fiber coarseness of from about 0.05 mg/m to about 0.5 mg/m, such as from 0.05 mg/m to 0.5 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.1 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.15 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.2 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.25 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.3 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.35 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.4 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg/m to 0.45 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.1 mg/m to 0.2 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.2 mg/m to 0.3 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.3 mg/m to 0.4 mg/m. In some aspects, the wood fibers have a fiber coarseness of 0.4 mg/m to 0.5 mg/m. For example, wood fibers used in the disclosed methods and compositions have a coarseness of 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45 or 0.5 mg/m.

Suitable wood fibers for use in the disclosed compositions and methods include softwood kraft pulp (Mercer Peace River Pulp, Inc.) comprising white spruce (Canada spruce) (>90%) and lodgepole pine (Contreta pine) (<10%), having a fiber length of 2.39 mm, a fiber width of 27.4 μm, a weight of 8.7 million fibers per gram, and a coarseness of 0.14 mg/m.

The composition of the present disclosure includes a binder, preferably from about 0.5% to about 50%, such as from 0.5% to 40%, such as from 0.5% to 30%, such as from 0.5% to 25%, such as from 0.5% to 20% by weight. In some aspects, the compositions of the present disclosure include 0.5% to 1% by weight binder. In some aspects, the compositions of the present disclosure include 0.5% to 5% by weight binder. In some aspects, the compositions of the present disclosure include 0.5% to 10% by weight binder. In some aspects, the composition of the present disclosure includes 0.5% to 15% by weight of binder. In some aspects, the compositions of the present disclosure include 0.5% to 20% by weight of binder. In some aspects, the compositions of the present disclosure include 5% to 10% by weight binder. In some aspects, the compositions of the present disclosure include 10% to 15% by weight binder. In some aspects, the compositions of the present disclosure include 15% to 20% by weight binder. For example, the compositions of the present disclosure are 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16. 5, 17, 17.5, 18, 18.5, 19, 19.5 or 20% by weight binder.

According to this disclosure, the binder can be polyvinyl alcohol (PVOH), ethylene vinyl alcohol copolymer (EVOH), starch (e.g., cooked or raw starch including corn starch and tapioca starch), polyvinyl acetate, ethylene vinyl acetate acrylic, dextrin, or combinations thereof. In some aspects, the binder comprises polyvinyl alcohol. In some aspects, the binder comprises an ethylene vinyl alcohol copolymer. In some aspects, the binder comprises starch. In some aspects, the binder comprises polyvinyl acetate. In some aspects, the binder comprises ethylene vinyl acetate acrylic. In some aspects, the binder comprises dextrin. In preferred aspects of the present disclosure, the binder is PVOH, EVOH, or a combination thereof. PVOH and/or EVOH are particularly preferred in the production of biodegradable and/or flexible products. In other embodiments where a stiffer product is desired, the binder can include starch. Binders suitable for use in the disclosed methods are available, for example, from Sekisui Specialty Chemicals America, Inc. (Dallas, Texas) and Kuraray Co., Ltd. (Tokyo, Japan). Preferred binders include Cellbol® Polyvinyl Alcohol 840, Cellbol® Polyvinyl Alcohol 540 and Cellbol® Polyvinyl Alcohol 805. The compositions of the present disclosure also include a surfactant in an amount of about 0.2% to about 10%, preferably 0.2% to 10% by weight. In some embodiments, the composition includes 0.2% to 1% surfactant by weight. In some embodiments, the composition includes 0.2% to 5% by weight surfactant. In some embodiments, the composition includes 0.5% to 5% by weight surfactant. In some aspects, the composition includes 1% to 5% by weight of surfactant. In some aspects, the composition includes 5% to 10% by weight of surfactant. For example, the compositions of the present disclosure can include 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, or 10% by weight surfactant.

Surfactants suitable for use in the disclosed compositions can be anionic surfactants, cationic surfactants, amphoteric surfactants, or combinations thereof. In some aspects, the surfactant comprises an anionic surfactant. In some aspects, the surfactant comprises a cationic surfactant. In some aspects, the surfactant comprises an amphoteric surfactant.

Surfactants suitable for use in the disclosed method include sodium dodecyl sulfate, dioctyl sodium sulfosuccinate, dodecyldimethylamine oxide (DDAO), stearyl alcohol, glyceryl laurate, polysorbate, cetostearyl alcohol, starch, sucrose, hexadecyl palmitate, lauryldimethylamine oxide (LDAO), coamidopropyl betaine (CAPB), ethanolamine, sorbitol, ethylenediaminetetraacetic acid dihydrogen dihydrogen sodium, sulfosuccinate, or combinations thereof. A preferred surfactant for use in the disclosed method is Aerosol® OT-75 (Solvay). A preferred surfactant for use in the disclosed method is Ammonix® (Stefan Corporation). Another preferred surfactant for use in the disclosed method is Amphosol® (Stefan Corporation). Another preferred surfactant for use in the disclosed method is Ammonix® Lo Special (Stefan Corporation). Another preferred surfactant for use in the disclosed method is Cocamidopropyl Betaine Amphosol GC-50® (Stephen Corp.). Another preferred surfactant for use in the disclosed method is cocamidopropyl betaine.

Compositions of the present disclosure also include water, preferably from about 10% to about 95%, eg, from 10% to 95% by weight. The water can be any water typically used in the manufacture of paper products and can include fresh water, spring water, purified water, distilled water, reverse osmosis water, and the like. Those skilled in the art will appreciate that the water used in the compositions and methods of the present disclosure may contain trace amounts of minerals, inorganic compounds, and organic compounds. In some embodiments, the composition includes 10% to 20% water by weight. In some aspects, the compositions of the present disclosure include 20% to 30% water by weight. In some aspects, the compositions of the present disclosure include 30% to 40% water by weight. In some aspects, the compositions of the present disclosure include 40% to 50% water by weight. In some aspects, the compositions of the present disclosure include 50% to 60% water by weight. In some aspects, the compositions of the present disclosure include 60% to 70% water by weight. In some aspects, the compositions of the present disclosure include 70% to 80% water by weight. In some aspects, the compositions of the present disclosure include 85% to 95% water by weight. In some aspects, the compositions of the present disclosure include 10% to 50% water by weight. In some aspects, the compositions of the present disclosure include 50% to 95% water by weight. In some aspects, the compositions of the present disclosure include 25% to 50% water by weight. In some aspects, the compositions of the present disclosure include 50% to 75% water by weight. For example, compositions of the present disclosure can include 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95% by weight water.

In some aspects, the compositions of the present disclosure consist of wood fiber, binder, surfactant and water. In other aspects, the compositions of the present disclosure consist essentially of wood fibers, binders, surfactants, water, and additional elements that do not substantially affect the basic and novel properties of the compositions used to make padded packaging materials.

In some aspects, compositions of the present disclosure comprise wood fibers, binders, surfactants, water, and additives (ie, one or more additives). Those compositions containing additives contain a non-zero weight percent of the additive up to 30 weight percent. An additive can include a single additive, or an additive can include two or more additives. When the composition of the present disclosure includes more than one additive, the total amount of additives is from non-zero weight percent to 30 weight percent. In some aspects, the composition includes no more than 30% by weight of additives. In some aspects, the composition includes no more than 25% by weight of additives. In some aspects, the composition includes no more than 20% by weight of additives. In some aspects, the composition includes no more than 15% by weight of additives. In some aspects, the composition includes no more than 10% by weight of additives. In some aspects, the composition includes no more than 5% by weight of additives. In some embodiments, the composition includes no more than 2 wt% additive. For example, the compositions of the present disclosure have a non-zero weight percent that is less than 0.1 weight percent, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11 , 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, 26, 26.5, 27, 27 .5, 28, 28.5, 29, 29.5 or 30% by weight of additives can be included. The composition of the present disclosure has a 3, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, 26, 26.5, 27, 27.5, 28, 28.5, 29, 2 Additives up to 9.5 or 30% by weight can be included.

Additives suitable for use in the compositions of the present disclosure include salts, starches, non-expanded microspheres, expanded microspheres, calcium carbonate, clays, nanocellulose, nanocrystalline cellulose, UV dyes, dyes, pigments, antifoams, humectants, waxes, phase change materials, microencapsulated chemicals, plasticizers, tackifiers, adhesion promoters (e.g., EGDA, PEI), crosslinkers, polyether compounds, rheology modifiers, preservatives, biocides, or combinations thereof.

Microspheres suitable for use in the products of the present disclosure are described, for example, in US Published Application No. 20190284438, US Published Application No. 20190062028, and US Patent No. 10,100,204, which are incorporated herein by reference in their entirety.

Rheology modifiers, also called thickeners or viscosity modifiers, are known in the art and include, for example, waxes, wax dispersions, hydroxyethylcellulose, methylcellulose, polyacrylic acid thickeners, xanthan gum, raw starch, cooked starch, or combinations thereof.

In some aspects, the compositions of the present disclosure do not include additives that are inorganic ionic salts, ie, the compositions of the present disclosure can include about 0% by weight of inorganic ionic salts.

In some aspects, the compositions of the present disclosure include additives that are inorganic ionic salts. Compositions that include additives that are inorganic ionic salts are particularly preferred in embodiments of the present disclosure in which the intermediate foam is microwave heated. Without being bound by a particular theory, it is believed that inorganic ionic salts can promote rapid temperature increases during microwave heating to produce the hyperexpanded foams of the present disclosure. In these aspects, the inorganic ionic salt may be present in the composition in an amount up to 30% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 25% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 20% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 15% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 10% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 5% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 4% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 3% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 2% or less by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of 1% or less by weight. In other aspects, the compositions of the present disclosure have a maximum 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, 26, 26.5, 27, 27.5, 28, 28. 5, 29, 29.5 or 30 weight percent inorganic ionic salts can be included. Inorganic ionic salts suitable for use in the compositions of the present disclosure include sodium chloride, calcium chloride, magnesium chloride, aluminum nitrate, ammonium zirconium, or combinations thereof. Sodium chloride is a particularly preferred inorganic ionic salt. While not wishing to be bound by any particular theory, it is believed that the addition of suitable inorganic ionic salts can facilitate drying of intermediate foams made from the compositions of the present disclosure using the methods described herein. RF treatment is believed to provide a sufficiently rapid temperature rise to produce the hyperexpanded foams of the present disclosure without the addition of inorganic ionic salt additives. Nevertheless, the RF-treated composition can optionally include inorganic ionic salt additives.

Also within the scope of this disclosure are dry pulp compositions that can be hydrated or rehydrated to produce the desired compositions described herein upon the addition of a predetermined amount of water. This includes 1% to 40% by weight wood fiber, 0.5% to 20% binder, 0.2% to 10% surfactant, and up to 30% by weight optional additives. Water can later be added to this dry pulp composition to (re)hydrate and then aerate (or (re)hydrate and aerate at the same time) to form an intermediate foam. In one aspect, rehydration and aeration of the wood fibers in this method is more rapid. In one aspect, a solution comprising 0.5% to 20% by weight of binder, 0.2% to 10% by weight of surfactant, and up to 30% by weight of optional additives may be applied (e.g., by spraying, soaking, dipping, etc.) to wood fibers or wood sheets/mass containing wood fibers to form the compositions described herein. The final content of wood fibers on a total basis is between 1% and 40% by weight.

In another embodiment, a two-part kit; for example, one part of the kit can include binders, surfactants, and optional additives, and this kit can be combined (e.g., by spraying, soaking, dipping, etc.) with other parts of the kit including wood fibers to hydrate and aerate the combined kit to produce an intermediate foam. The components of the two-part kit may be varied to suit transportation and storage needs. It is also envisioned that 3-part or 4-part kits may be constructed to suit transportation and storage needs. Compositions made in this manner can be used in any of the methods described herein.

Compositions of the present disclosure, which include 1% to 40% by weight wood fiber, 0.5% to 20% binder, 0.2% to 10% surfactant, 10% to 95% water, and up to 30% optional additives by weight, can be mixed and combined (i.e., aerated) with air to form an intermediate foam using methods known in the art for incorporating air into aqueous compositions. In one embodiment, the wood fibers are mechanically disassembled from their original compact shape prior to mixing and aeration. In another embodiment, the mixing and aeration steps simultaneously mechanically degrade the wood fibers, depending on the speed of mixing and aeration. In some aspects, air is added to the material until the total volume percent of air is 95%. As used herein, "% by volume of air" in a formulation is calculated according to the following formula.

In some aspects, the intermediate foam has the consistency and appearance of a commercial shaving cream foam or personal care mousse. In another aspect, the intermediate foam has the consistency and appearance of a pancake batter.

Intermediate foams made in accordance with the present disclosure can contain from about 10% to about 95% by volume air, such as from 10% to 95% by volume. In some aspects, the intermediate foam contains 10% to 50% air by volume. In some aspects, the intermediate foam contains 50% to 95% air by volume. In some aspects, the intermediate foam contains 20% to 95% air by volume. In some aspects, the intermediate foam contains 30% to 80% air by volume. In some aspects, the intermediate foam contains 40% to 50% air by volume. In some aspects, the intermediate foam contains 50% to 90% air by volume. In some aspects, the intermediate foam contains 70% to 95% air by volume. For example, an intermediate foam made according to the present disclosure can contain 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 volume percent air.

Intermediate foams of the present disclosure can be produced by combining air with the compositions of the present disclosure using one or more methods known in the art. Suitable methods of mixing air include, for example, injection, mixing, shearing, paddle mixing, cowl mixing, gate mixing, auger mixing, or combinations thereof.

An intermediate foam made according to the disclosed method has a viscosity of about 3,000 to about 100,000 cPs, such as 5,000 to 100,000 cPs at 25°C to 40°C. Viscosity can be measured using methods known in the art. In some aspects, an intermediate foam made according to the disclosed method has a viscosity of 5,000 to 100,000 cPs at 25°C. In some embodiments, intermediate foams made according to the disclosed methods have viscosities of 5,000 to 100,000 cPs at 40°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 5,000 to 10,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 10,000 to 20,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 20,000 to 30,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 30,000 to 40,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 40,000 to 50,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 50,000 to 60,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 60,000 to 70,000 cPs at 25°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 70,000 to 80,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 80,000 to 90,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 90,000 to 100,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 5,000 to 50,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 50,000 to 100,000 cPs at 25°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 25,000 to 50,000 cPs at 25°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 50,000 to 75,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 75,000 to 100,000 cPs at 25°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 5,000 to 10,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 10,000 to 20,000 cPs at 40°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 20,000 to 30,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 30,000 to 40,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 40,000 to 50,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 50,000 to 60,000 cPs at 40°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 60,000 to 70,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 70,000 to 80,000 cPs at 40°C. In some aspects, intermediate foams made according to the present disclosure have a viscosity of 80,000 to 90,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 90,000 to 100,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 5,000 to 50,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 50,000 to 100,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 25,000 to 50,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 50,000 to 75,000 cPs at 40°C. In some aspects, an intermediate foam made according to the present disclosure has a viscosity of 75,000 to 100,000 cPs at 40°C. For example, intermediate foams made in accordance with the present disclosure have temperatures of 5,000, 10,000, 15,000, 20,000, 25,000, 30,000, 35,000, 40,000, 45,000, 50,000, 55,000, 60,000, 65,000, 70,000, 75,000, 80 at 25°C. ,000, 85,000, 90,000, 95,000 or 100,000 cPs. In other aspects, intermediate foams made in accordance with the present disclosure have a , 80,000, 85,000, 90,000, 95,000 or 100,000 cPs.

Intermediate foams produced according to the methods of the present disclosure can have densities from about 0.5 lbs/gallon to about 5 lbs/gallon, such as from 0.5 lbs/gallon to 5 lbs/gallon. In some aspects, intermediate foams produced according to the methods of the present disclosure have densities from 0.5 lbs/gallon to 3 lbs/gallon. In some aspects, intermediate foams produced according to the methods of the present disclosure have densities between 3 lbs/gallon and 5 lbs/gallon. For example, intermediate foams produced according to the methods of the present disclosure have densities of 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5 and 5 pounds per gallon.

As part of a process for making packaging material, the intermediate foam of the present disclosure can be applied to a first web substrate, also referred to herein as the first layer or first ribbon. The first web substrate has a top surface and a bottom surface and a width defining a perimeter.

The intermediate foam can be applied to the first web substrate using any method known in the art, such as rolling, dripping, discrete application, and the like. In some aspects, the intermediate foam is applied using nozzles oriented perpendicular to the first web substrate. Intermediate foams can be applied in discrete elements, for example, randomly or in patterns such as patterns of dots, lines, squares, triangles, and the like.

The first web substrate can include any web material suitable for manufacturing packaging materials. For example, the first web substrate may be paper, corrugated cardboard, compostable polymeric films (e.g., Scofilm and Ecoworks from Cortec; Nativia from Tagleaf Industries; Natureflex from Futamura), biodegradable polymeric films, bio-based films (e.g., polylactic acid films); Earth Coating® from Recta), recyclable metallized paper (eg, Metal Back F from Recta), or combinations thereof.

Intermediate foams produced using the compositions and methods of the present disclosure can be treated to remove water. In a preferred embodiment, the intermediate foam is treated such that liquid water present in the intermediate foam is converted to water vapor and/or steam that is released into the atmosphere. Intermediate foam that has been treated to remove liquid water is also referred to herein as dried and is sometimes referred to herein as "dry foam" or "hyperexpansion foam." This treatment removes substantially all water from the intermediate foam. For example, this treatment removes up to 100% by weight of water in the intermediate foams of the present disclosure. In another aspect, the treatment removes up to 99% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 95% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 90% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 85% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 80% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 75% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 70% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 65% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 60% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 55% by weight of water in the intermediate foams of the present disclosure. In other aspects, the treatment removes up to 50% by weight of water in the intermediate foams of the present disclosure.

Various methods of removing liquid water (ie, drying) from the intermediate foams disclosed herein can be used. In some aspects, the intermediate foams of the present disclosure are treated at ambient temperature and humidity to remove water. In some aspects, the intermediate foam is treated with conventional heat to remove water. In other embodiments, the drying method does not include conventional heating, such as using an oven that produces a heating temperature of about 100°C to about 450°C.

In some aspects, the intermediate foam produced using the compositions and methods of the present disclosure can be dried using dielectric heat. In these methods, the intermediate foam is converted into a hyperexpansion foam. While not wishing to be bound by any particular theory, it is believed that the liquid water entrapped between the wood fiber layers of the intermediate foam is rapidly converted to water vapor and/or steam causing the intermediate foam to expand as the water vapor and/or steam is released from the intermediate foam resulting in a hyperexpanded (dry) foam.

The % total volume increase of the hyperexpanded foams of the present disclosure can be determined by measuring (e.g., with calipers or micrometers) in the x, y, and z directions of the hyperexpanded foams and comparing to the x, y, and z direction measurements of the intermediate foams prior to dielectric treatment. The volume of hyperexpanded foam can be determined according to the following formula using measurements taken with a caliper or micrometer:
X measurement x Y measurement x Z measurement = foam volume

The hyperexpanded foams of the present disclosure exhibit a total volume % increase of at least 5% by volume, ie, a total volume % increase, compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of up to 1000% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 10% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 15% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a total % volume increase of at least 20% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 25% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a total % volume increase of at least 30% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 35% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 40% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 45% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a total % volume increase of at least 50% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 55% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 60% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 65% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a total % volume increase of at least 70% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 75% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a total % volume increase of at least 80% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 85% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 90% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 95% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 100% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 110% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 120% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 130% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 140% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 150% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 160% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 170% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 180% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 190% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 200% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 210% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 220% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 230% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 240% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 250% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 260% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 270% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 280% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 290% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a total % volume increase of at least 300% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 310% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 320% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 330% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 340% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 350% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 360% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 370% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 380% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 390% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 400% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 410% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 420% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 430% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 440% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 450% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 460% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 470% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 480% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a % total volume increase of at least 490% by volume compared to the volume of the intermediate foam. In some aspects, the hyperexpanded foams of the present disclosure exhibit a total % volume increase of at least 500% by volume compared to the volume of the intermediate foam.

Dielectric heating of the intermediate foam of the present disclosure, when performed for a preselected time using a preselected frequency, results in expansion of the intermediate foam in each of the x, y and/or z directions, producing a hyperexpanded foam having a lower water content as compared to the initial intermediate foam. Treatment of the intermediate foam of the present disclosure using non-dielectric heat or treatment with dielectric heat outside the frequency and time ranges of the present disclosure will not result in expansion of the intermediate foam to form a hyperexpanded foam.

Dielectric heating, electronic heating, radio frequency (RF) heating, and radio frequency heating are all used interchangeably herein and are processes in which high frequency alternating electric fields or radio waves heat a dielectric material. Industrial radio frequencies operate from about 2 MHz to 300 MHz, with typical wavelengths from about 141 to about 24 feet (43 to 7.3 meters). Preferred RF frequencies include frequencies below 100 MHz, such as 13.56, 27.12, and 40.68 MHz.

In some aspects, the intermediate foam produced using the compositions and methods of the present disclosure can also be dried using dielectric heating, which is microwave heating, to produce a hyperexpanded foam. Microwave heating expands the intermediate foam in each of the x, y and/or z directions to produce a hyperexpanded foam. Industrial microwave systems use frequencies above 300 MHz, with typical wavelengths of about 13-5 inches (33-12 cm). Preferred microwave frequencies include 915 MHz and 2750 MHz.

In another aspect, the intermediate foam is dried using a combination of dielectric heating and conventional heating. For example, an intermediate foam of the present disclosure can be treated with dielectric heating in a first processing step to form a hyperexpanded foam, and the resulting hyperexpanded foam can be treated with conventional heating in a second processing step. In another aspect, the intermediate foam is treated with a combination of dielectric heating, conventional heating, and ambient temperature/humidity. For example, the intermediate foam of the present disclosure can be processed by dielectric heating in a first processing step, the resulting super-expanded foam heated by conventional heating in a second processing step, and then the conventionally heated hyper-expanded foam can be processed in a third processing step at ambient temperature/humidity.

Intermediate foams of the present disclosure expand in each of the x, y and/or z directions when heated using dielectric heating (eg, RF, microwave) to produce hyperexpanded foams. In some aspects, the intermediate foams of the present disclosure expand at least 20% by volume in the x, y, or z directions to produce hyperexpanded foams. In some aspects, the intermediate foam can expand up to 200% in the x-direction, up to 200% in the y-direction, and/or up to 200% in the z-direction to create a super-expanded foam.

In some aspects, the intermediate foam can expand up to 150% in the x-direction to create a super-expanded foam. In some aspects, the intermediate foam can expand up to 100% in the x-direction to produce a hyperexpanded foam. In some aspects, the intermediate foam can expand up to 50% in the x-direction to create a hyperexpanded foam. In some aspects, the intermediate foam can expand between 10% and 50% in the x-direction to produce a hyperexpansion foam. In some aspects, the intermediate foam can expand 20% to 40% in the x-direction to produce a hyperexpansion foam. For example, an intermediate foam of the present disclosure can expand 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50% in the x-direction to produce a hyperexpanded foam.

In some aspects, the intermediate foam can expand in the y-direction by 5% to 50%, such as 10% to 50%, to produce a hyperexpanded foam. In some aspects, the intermediate foam can expand up to 200% in the y-direction to create a super-expanded foam. In some aspects, the intermediate foam can expand up to 100% in the y-direction to create a super-expanded foam. In some aspects, the intermediate foam can expand up to 50% in the y-direction to create a super-expanded foam. In some aspects, the intermediate foam can expand between 15% and 35% in the y-direction to produce a hyperexpansion foam. For example, an intermediate foam of the present disclosure can expand 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50% in the y-direction to produce a hyperexpanded foam.

In some aspects, the intermediate foam can expand up to 200% in the z-direction to create a super-expanded foam. In some aspects, the intermediate foam can expand up to 100% in the z-direction to produce a super-expanded foam. In some aspects, the intermediate foam can expand up to 50% in the z-direction to produce a super-expanded foam. In some aspects, the intermediate foam can expand between 5% and 50% in the z-direction to produce a hyperexpanded foam. In some aspects, the intermediate foam can expand from 1% to 25%, such as from 5% to 25%, in the z-direction to create a hyperexpanded foam. For example, an intermediate foam of the present disclosure can expand 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50% in the z-direction to produce a hyperexpanded foam.

In some aspects, the intermediate foam expands about 35% in the x-direction, about 30% in the y-direction, and about 20% in the z-direction when heated using dielectric heat (e.g., RF or microwave) to produce a hyperexpanded foam. In some aspects, the intermediate foam expands about 23% in the x-direction, about 99% in the y-direction, and about 11% in the z-direction when heated using dielectric heat (e.g., RF or microwave) to produce a hyperexpanded foam. See, eg, FIGS. 4A, 4B, 5A, and 5B.

Conventional heating of the disclosed intermediate foam does not produce hyperexpansion of the intermediate foam in each of the x, y and/or z directions to the same extent that dielectric heating (eg, RF, microwave) produces. Therefore, conventional heating of the compositions of the present disclosure, without treatment with dielectric heating, does not produce hyperexpanded foams within the scope of the present disclosure.

Products made by applying an intermediate foam of the present disclosure to a first web substrate are within the scope of the present disclosure. Also within the scope of the present disclosure are products produced by applying an intermediate foam of the present disclosure to a first web substrate and applying dielectric heat to the intermediate foam, or applying dielectric heat to the intermediate foam and the first web substrate to expand the intermediate foam in each of the x, y and/or z directions to create a hyperexpanded foam.

Laminated products are also within the scope of this disclosure. According to this disclosure, a "laminated" product refers to a product having a foam (eg, intermediate foam or hyperexpanded foam) of the present disclosure sandwiched between surfaces of one or more web substrates. Some laminated products of the present disclosure are single laminated products having a foam of the present disclosure (eg, intermediate foam or hyperexpansion foam) sandwiched between surfaces of one web substrate. In other aspects, a single laminate product has a foam of the present disclosure (eg, intermediate foam or hyperexpansion foam) sandwiched between two different web substrate surfaces.

In some aspects, these single laminate products comprise a first web substrate having an intermediate foam of the present disclosure applied with an adhesive applied to the first web substrate, and a second web substrate applied to the intermediate foam, the laminate optionally being treated with dielectric heating to produce a hyperexpansion foam. Adhesive is applied to at least a portion of a first web substrate, eg, at least a portion of the perimeter of the first web substrate, and adhesive is applied to a second web substrate to form a laminated product. The single laminate product can optionally be treated with conventional heating or dielectric heating. These single laminated products can be converted into packages such as envelopes and pouches.

In other aspects, a single laminate product may be produced by providing a first web substrate having an intermediate foam of the present disclosure applied thereto. In some embodiments, a single laminate product may be produced by folding the first web substrate at one seam, and the other two edges may be sealed together with an adhesive to form a pouch. It is also envisioned that a pressure sensitive adhesive strip may be attached to the last remaining edge to seal the pouch to form a sealed package. The pressure sensitive adhesive may have a liner cover that may be removed at a later time and the remaining sides (edges) sealed closed. Laminated products containing the intermediate foam of the composition (optionally heated with dielectric heat to produce a hyperexpanded foam) may be the basis for forming products including envelopes, bags, pouches, boxes, cartons, cases, lids, wraps, clamshells, cups, and adhesive-backed food containers.

In some aspects, "multi-layer laminate" products can be made according to the methods of the present disclosure. A multi-layer laminate product is manufactured by combining two or more single laminate products of the present disclosure. The multilayer laminate product can optionally be dielectric heat treated. These multi-layer laminate products can be converted into packages such as, for example, envelopes or pouches. For example, a first single laminate product can be adhesively attached to three of the four sides of a second single laminate product to form a pouch. It is also envisioned that a pressure sensitive adhesive strip may be attached to the last remaining edge to seal the pouch to form a sealed package. The pressure sensitive adhesive may have a liner cover which may be removed at a later time and the remaining sides (edges) sealed closed. A multi-layer laminate product containing the foam of the composition (optionally dielectrically heated) may be the basis for forming products including envelopes, bags, pouches, boxes, cartons, cases, lids, wraps, clamshells, cups, and adhesive-backed food containers.

In some aspects, the intermediate foams of the present disclosure can be applied to remain within preselected locations on the web substrate. Adhesion of the intermediate foam of the present disclosure to the web substrate can be adjusted by adjusting the type and amount of each component of the intermediate foam. In some embodiments, the adhesion of the intermediate foam can be adjusted simply by adjusting the type and amount of binder. In some embodiments, additives can be tailored to include ingredients that increase or decrease adhesion. In other aspects, the adhesion of the intermediate foam to the web substrate is adjusted, for example, by applying an adhesive before or after application of the intermediate foam to the web substrate, hydrogen bonding between the web substrate and the intermediate foam, or combinations thereof. It is desirable that the hyperexpansion foam remain adhered to the web substrate even after application of compression and/or shear.

Products manufactured according to the methods of the present disclosure may include an adhesive. Adhesives are known in the art and include, for example, water-based adhesives, solvent-based adhesives, hot melt adhesives, and pressure sensitive adhesives. Adhesives used in the products described herein may be made from renewable, compostable, or biodegradable materials to further reduce the carbon footprint of the final product. Hot melt adhesives and water-based adhesives are contemplated as they can be processed at the same time that the intermediate foams of the present disclosure are processed with conventional heating or dielectric heating. When the intermediate foam is treated with conventional heating or dielectric heating, the hot melt adhesives and water-based adhesives cure and adhere the substrates. Preferred adhesives suitable for use in the disclosed products include, for example, adhesives comprising ethylene-vinyl acetate (EVA), polyvinyl acetate (PVA), polyvinyl alcohol (PVOH), ethylene vinyl alcohol copolymer (EVOH), acrylics, acrylates, polyurethanes (PUR), epoxies, polyolefins, and combinations thereof.

Products made using the compositions, intermediate foams, hyperexpansion foams, and methods of the present disclosure include padded envelopes and other paper packaging products. Products made in accordance with the present disclosure may be highly recyclable in conventional paper waste streams. Products made according to the present disclosure may be biodegradable. Biodegradability standards include OECD 301, 304A, and 306. Products made according to the present disclosure are compostable. Composting standards include ISO 17088, ISO 18606, ASTM D6400, and ASTM D6868. Products made according to the methods of the present disclosure may also conform to ASTM D5929-18.

In some embodiments, a concentrated composition comprising binders, surfactants, and optional additives, and optionally water, as described herein, can be prepared and applied (e.g., by spraying, coating, dipping, impregnating, etc.) to a wood fiber-containing substrate, such as a paper pulp sheet or a veil of paper pulp sheets containing wood fibers. These concentrated compositions are also within the scope of this disclosure. The resulting paper pulp sheet or paper pulp bale, to which the binder, surfactants, optional additives, and optional water concentrate composition have been applied, can be dried using conventional methods. The resulting paper pulp sheets and paper pulp bales treated with the concentrate compositions described herein are also within the scope of the present disclosure. The amount of binder, surfactant, and any additives in these compositions is that the composition obtained is a wooden fiber of one % to 40 % by weight, 0.5 % by weight, a binder of 0.5 % by weight to 20 % by weight, when the amount of dried paper pulp sheet or paper pulpbert is applied. This is the amount that includes a surfactant of 0.2 % to 10 % by weight, 10 % to 95 % by weight, and any additives of up to 30 % by weight. The resulting compositions can be used in any of the methods described herein to make intermediate and hyperexpansion foams that can be used to make packaging materials.

The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention described and claimed herein.

[Example 1]
Wood fibers are soaked in water and mechanically disassembled from their original compact shape. Binders, surfactants, and optional additives are added. The mixture is mechanically mixed and aerated until the desired air content is reached. The blade or mixing process can incorporate appropriate fiber disintegration, mixing, and air content. Higher speeds may be required to completely separate the fibers and produce a foam with the overall consistency and appearance of a personal care mousse, such as shaving cream. No chemical blowing agents or blowing agents are required.

After mixing and aeration, additional air can be injected into the foam as it is transported. Materials can be transported using, for example, diaphragm pumps, gear pumps, auger systems, rotary tubes, high shear mixers, gravity feed, vacuum, and the like. The resulting intermediate foam is transferred to a single or multiple transport system for application to a web substrate.

Application to the web substrate may occur with or without contact with the web substrate. The intermediate foam can be extruded in a specific shape or press to achieve the desired size/shape element. The intermediate foam can optionally be metered into an open web substrate by a press, extrusion device, or open channel into a preselected shape on the web substrate. The intermediate foam can be applied in strips, stripes, dots, patterns, or in combination with multiple element shapes/sizes.

The intermediate foam is applied in a discontinuous pattern in the web or cross-web direction. Preferred patterns contain elements less than 0.5 inches in shortest dimension and 1.5 inches or less in longest dimension. The spacing between intermediate foam pattern elements depends on the thickness of the intermediate foam applied. Preferably, the thickness is from about 0.1 inch to about 0.5 inch. For example, see FIG.

[Example 2]
After the intermediate foam is applied to the web substrate, the converter should not apply excessive pressure to the intermediate foam. If laminated, minimal compression is applied where the intermediate foam is applied. Pressure is optionally applied to the edges of the web substrate to ensure adequate closure of the system while maintaining thickness.

[Example 3]
The intermediate foam is dried using one or more methods. The RF and microwave drying parameters are shown in the table in Example 4. Depending on the drying method, hyperexpanded foams can be produced that have a larger volume compared to the volume of the intermediate foam. Hyperexpansion foam is flexible and bends with average hand pressure. The initial general shape of the intermediate foam is maintained after the dielectric heat treatment and most of the hyperexpansion foam material remains in place during packaging and use.

[Example 4]

[Example 5]

For Example 5, an intermediate foam was prepared by mixing each component for 11 minutes using a hand mixer and paddle mixer. The resulting Example 5 intermediate foam had a viscosity of about 30,000 cP and a density of 3.6 pounds per gallon (wet). A 0.5 wet gram dot of intermediate foam was applied to the paper substrate and then placed in a 1000 watt microwave oven for about 5 minutes. Upon microwave heating of Example 5, a size increase of less than 20% was observed in the x, y and z directions.

A 0.5 wet gram dot of the intermediate foam of Example 5 took 17 minutes to dry in a 375°F convection oven. A 37 wet gram dot of intermediate foam took 1.5 hours (90 minutes) to dry in an oven at 375°F. See Figure 2.

The material resulting from microwave treatment was stiff with minimal flexibility. A force of approximately 140 grams per millimeter was required to compress the material obtained from microwave treatment when tested with a Texture Analyzer. The general shape of the element was maintained throughout the drying process. For example, see FIG.

[Example 6]

An intermediate foam made according to Example 6 had a viscosity of about 20,000 cPs. The intermediate foam had a low foam volume with a density of 6.0 lbs/gallon. Example 6 had a higher visual foam peak initially compared to the non-aerated composition, but its volume decreased as all the ingredient materials were combined. Prior to the addition of NaCl, the density of the intermediate foam material was approximately 1.3 pounds per gallon. See FIG.

A 0.5 g dot of the intermediate foam of Example 6 was formed on paper and then microwaved for about 5 minutes. A 0.5 gram wet dot of intermediate foam had a 1% decrease in the x direction, a 6% increase in the y direction, and a 3% increase in the z direction. After drying, the total volume increase % of the microwave treated foam was 4% by volume.

Processing the intermediate foam of Example 6 in a conventional oven required 10 minutes at 375° F. for a 0.5 gram element.

[Example 7]

The intermediate foam produced in Example 7 had a viscosity of about 20,000 cPs and a wet density of 1.1 lbs/gallon. The intermediate foam of Example 7 was applied in 0.5 gram dots onto a paper substrate and treated with microwaves at 1000 watts for about 30 seconds to produce a hyperexpanded foam. When treated with microwaves, the material increases in volume and retains the overall shape of the element, resulting in a hyperexpanded foam. The hyperexpansion foam adhered to the paper substrate and remained stationary when moved. The hyperexpansion foam was flexible and required approximately 4 grams of compression per millimeter.

A 2-inch long line in which 0.5 grams of intermediate foam was processed (e.g., dried) to produce hyperexpanded foam had volume increases of 18% in the x-direction, 84% in the y-direction, and 66% in the z-direction. For a 2 inch long line of 1.0 wet grams, the intermediate foam increased 23% in the x direction, 115% in the y direction, and 87% in the z direction when dried to produce a hyperexpanded foam. See FIG.

When measured in calipers/micrometers in the X, Y, and Z directions and compared to measurements of a 2 inch long line of intermediate foam using 0.5 grams of material, the % volume increase of the hyperexpanded foam showed a 240% volume increase for the hyperexpanded foam compared to the volume of the intermediate foam. The % volume increase of the hyperexpansion foam when compared to the intermediate foam is 360% volume increase compared to the intermediate foam. See FIG.

[Example 8]

The ingredients were uniformly mixed and the resulting intermediate foam of Example 8 had a final viscosity of 15,000 cPs. The intermediate foam density was 1.4 lbs/gallon. When the intermediate foam was applied to the web substrate in discrete pattern elements, the intermediate foam maintained its general shape and structure. After microwave treatment, the intermediate foam increased in size in the x, y and z directions to produce a super expanded foam. The stiffness of the hyperexpanded foam was about 68 grams per millimeter as assessed by a texture analyzer. See FIG.

[Example 9]

The ingredients were uniformly mixed and the resulting intermediate foam of Example 9 had a final viscosity of about 4,000 cPs. The final density of the intermediate foam was 1.2 lbs/gallon. The intermediate foam maintained its general shape and structure when applied to the paper substrate in discrete patterns. The intermediate foam after microwave treatment produced the super expanded foam of Example 9. The volume increase from the intermediate foam to the hyperexpanded foam after microwave treatment was greater than 4% in each direction. The hyperexpansion foam remained flexible after drying.

A 0.5 gram element of the intermediate foam of Example 9 was processed in a conventional oven at 375° F. for 10 minutes. No increase in size was observed when the intermediate foam was dried in the oven. A reduction in height (z-direction) was observed when the intermediate foam was dried using a conventional oven. An increase in size to produce a hyperexpanded foam was observed only when the intermediate foam was treated with microwaves.

[Example 10]

The ingredients were uniformly mixed and the resulting intermediate foam of Example 10 had a final viscosity of about 11,000 cPs. The final density of the intermediate foam was 1.4 lbs/gallon. The intermediate foam was not stable during application and the wood fibers were not evenly distributed in the intermediate foam. When the intermediate foam sample was applied to the paper substrate, the intermediate foam dried quickly and when applied to the substrate in discrete elements, the intermediate foam maintained its overall shape and structure. The hyperexpanded foam showed a slight increase in size in the x, y and z directions after microwave drying to produce a hyperexpanded foam. The total thickness of the final laminate (dry) was about 0.20 inch. Microwave treatment of 0.5 grams of wet dots of intermediate foam for about 3 minutes removed most of the water from the intermediate foam and produced a hyperexpanded foam. See FIG. 10A. Processing a 0.5 gram sheet of wet dots of the intermediate foam of Example 10 in a conventional oven required 10 minutes at 375° F. and did not produce a hyperexpansion foam. See Figure 10B.

[Example 11]

An intermediate foam made according to Example 11 had a density of 0.88 lbs/gallon and a viscosity of about 25,000 cPs. The intermediate foam of Example 11 was laid down on a paper substrate at 0.25 wet gram dots and dried in a 1000 Watt microwave at (i) 100% power and (i) 30% power.

Intermediate foams treated with 1000 Watt microwaves at 30% power for about 60 seconds produced hyperexpanded foams with 10-15% by weight moisture in the sample. A 0.25 wet gram sample of the intermediate foam grew 19% in the x direction, 24% in the y direction, and decreased 22% in the z direction when the hyperexpanded foam was produced. The overall average volume increase of the hyperexpanded foam was 46% compared to the volume of the intermediate foam. See FIG. 11A.

A 0.25 wet dot of intermediate foam treated with the same microwave at 100% power for 30 seconds produced a hyperexpanded foam with 10-15% moisture by weight. The 0.25 gram intermediate foam sample had a 43% increase in the X direction, a 28% increase in the y direction, and a 5% increase in the Z direction compared to the intermediate foam. The overall average volume increase of the hyperexpanded foam was 182% compared to the volume of the intermediate foam. See FIG. 11B.

Claims (49)

1% to 40% by weight of wood fiber,
0.5% to 20% by weight of a binder;
0.2% to 10% by weight of a surfactant;
A composition comprising 10% to 95% by weight water and 0% to 30% by weight additives. 2. The composition of claim 1, wherein the wood fibers are virgin hardwood, virgin softwood, regenerated hardwood, regenerated softwood, or mixtures thereof. 3. A composition according to claim 1 or 2, wherein the wood fibers are in the form of kraft pulp. The composition according to any one of claims 1 to 3, wherein the virgin pulp has a fiber length of 0.5 mm to 5 mm. A composition according to any one of the preceding claims, wherein the fiber width is 20-35 µm. A composition according to any one of the preceding claims, wherein said wood fibers are between 5 and 30 million fibers per gram. A composition according to any preceding claim, wherein the wood fibers have a fiber coarseness between 0.05 mg/m and 0.5 mg/m. A composition according to any preceding claim, wherein the binder is polyvinyl alcohol, ethylene-vinyl alcohol copolymer, starch, polyvinyl acetate, ethylene vinyl acetate acrylic, dextrin, or combinations thereof. A composition according to any preceding claim, wherein the surfactant is an anionic surfactant, a cationic surfactant, an amphoteric surfactant, or a combination thereof. 4. The surfactant of claim 1, wherein the surfactant is sodium dodecyl sulfate, dioctyl sodium sulfosuccinate, dodecyldimethylamine oxide (DDAO), stearyl alcohol, glyceryl laurate, polysorbate, cetostearyl alcohol, starch, sucrose, hexadecyl palmitate, lauryldimethylamine oxide (LDAO), coamidopropyl betaine (CAPB), ethanolamine, sorbitol, disodium dihydrogen ethylenediaminetetraacetate, or combinations thereof. 10. The composition according to any one of 1-9. The composition according to any one of claims 1 to 10, comprising not more than 2% by weight of additives that are inorganic ionic salts. 12. The composition of claim 11, wherein the inorganic salt is sodium chloride, calcium chloride, magnesium chloride, aluminum nitrate, ammonium zirconium, or combinations thereof. 13. The composition of any one of claims 1-12, comprising up to 30% by weight of additives including salts, starches, non-expanded microspheres, expanded microspheres, calcium carbonate, clays, nanocellulose, nanocrystalline cellulose, dyes, pigments, antifoams, humectants, waxes, phase change materials, microencapsulated chemicals, plasticizers, crosslinkers, preservatives, polyether compounds, or combinations thereof. A composition according to any one of the preceding claims, comprising up to 30% by weight of additives, including rheology modifiers. 15. The composition of Claim 14, wherein the rheology modifier is a wax, wax dispersion, hydroxyethylcellulose, methylcellulose, polyacrylic thickener, xanthan gum, starch, or combinations thereof. An intermediate foam comprising from 10% to 95% by volume air and from 90% to 5% by volume of the composition of any one of claims 1-15 or 48. 17. The intermediate foam of Claim 16, having a viscosity of 5,000 to 100,000 cPs at 25°C to 40°C. 18. The intermediate foam of claim 16 or 17, having a density of 0.5 lbs/gallon to 5 lbs/gallon. A method of making an intermediate foam comprising combining the composition of any one of claims 1-15 with air to form the intermediate foam. 20. The method of claim 19, wherein the combination comprises injection, mixing, shearing, paddle mixing, cowl mixing, gate mixing, auger mixing, or combinations thereof. An intermediate foam made according to the method of claim 19 or 20. 22. The intermediate foam of Claim 21, having a viscosity of 5,000 to 100,000 cPs at 25°C to 40°C. 23. The intermediate foam of claim 21 or 22, having a density of 0.5 lbs/gallon to 5 lbs/gallon. A method comprising applying an intermediate foam according to any one of claims 16-18 or an intermediate foam according to any one of claims 21-23 to a first web substrate. 25. The method of claim 24, wherein the first web substrate is paper, corrugated board, compostable polymer film, biodegradable polymer film, biofilm, cellophane, polyester film, polypropylene film, polyethylene film, metallized film, recyclable paper, recycled paper, recyclable coated paper, recyclable metallized paper, or combinations thereof. 26. The method of claim 24 or 25, further comprising drying the intermediate foam by applying dielectric heat to the intermediate foam, wherein the dielectric heat is RF or microwave. A product manufactured according to the method of any one of claims 24-26. 27. The method of any one of claims 24-26, further comprising applying an adhesive to at least a portion of the first web substrate. 29. The method of Claim 28, wherein the adhesive comprises EVA, PVA, PVOH, EVOH, acrylic, acrylate, PUR, or combinations thereof. 30. A product manufactured according to the method of claim 28 or 29. 30. The method of Claims 28 or 29, further comprising applying a second web substrate to the adhesive to form a laminate structure. 32. The method of claim 31, wherein the second web is paper, corrugated board, compostable polymer film, biodegradable polymer film, biofilm, cellophane, polyester film, polypropylene film, polyethylene film, metallized film, recyclable paper, recycled paper, recyclable coated paper, recyclable metallized paper, or combinations thereof. 33. A product manufactured according to the method of claim 31 or 32. 34. The product of claim 33 in the form of envelopes, pouches, bags, boxes, cartons, cases, lids, wraps, clamshells, cups, food containers with adhesive. 1% to 40% by weight of wood fiber,
0.5% to 20% by weight of a binder;
0.2% to 10% by weight of a surfactant;
preparing a composition comprising 10% to 95% by weight of water and 0% to 30% by weight of additives;
mixing and aerating the composition to form an intermediate foam;
applying the intermediate foam onto a web substrate; and heating the intermediate foam to substantially remove water;
heating the intermediate foam causes it to expand in volume and form a super-expanded foam;
A method of forming a hyperexpansion foam comprising: 36. A product manufactured according to the method of claim 35. 36. The method of Claim 35, further comprising applying an adhesive to at least a portion of the first web substrate. 38. The method of claim 37, wherein the first web substrate is paper, corrugated board, compostable polymer film, biodegradable polymer film, biofilm, cellophane, polyester film, polypropylene film, polyethylene film, metallized film, recyclable paper, recycled paper, recyclable coated paper, recyclable metallized paper, or combinations thereof. 38. The method of Claim 37, wherein the adhesive comprises EVA, PVA, PVOH, EVOH, acrylic, acrylate, PUR, epoxy, or polyolefin, or combinations thereof. A product manufactured according to the method of any one of claims 37-39. 40. The method of any one of claims 37-39, further comprising applying a second web substrate to the seam adhesive to form a laminated structure. 42. The method of claim 41, wherein the second web substrate is paper, corrugated board, compostable polymer film, biodegradable polymer film, biofilm, cellophane, polyester film, polypropylene film, polyethylene film, metallized film, recyclable paper, recycled paper, recyclable coated paper, recyclable metallized paper, or combinations thereof. 43. A product manufactured according to the method of claim 41 or 42. 43. The product of claim 42 in the form of envelopes, pouches, bags, boxes, cartons, cases, lids, wraps, clamshells, cups, food containers with adhesive. preparing a composition comprising wood pulp, a binder, a surfactant, water, and optional additives; and drying said composition using conventional or ambient heat to produce a dry pulp composition;
including
A method, wherein the addition of water to the dry pulp composition produces the composition of any one of claims 1-15. 46. A dry pulp composition produced according to the method of claim 45. A method comprising adding water to the dry pulp composition of claim 46 to produce the composition of any one of claims 1-15. 48. A composition made according to the method of claim 47. A method comprising combining a two-part kit, said two-part kit comprising (i) a first part comprising a binder, a surfactant, and optional additives, and (ii) a second part comprising wood fibers,
A method wherein water is added to the mixture to produce the composition of any one of claims 1-15.

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